US8037843B2 - Resin application and infusion system - Google Patents

Resin application and infusion system Download PDF

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Publication number
US8037843B2
US8037843B2 US12/575,668 US57566809A US8037843B2 US 8037843 B2 US8037843 B2 US 8037843B2 US 57566809 A US57566809 A US 57566809A US 8037843 B2 US8037843 B2 US 8037843B2
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Prior art keywords
fiber tows
resin
nozzles
rods
infusion system
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US12/575,668
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US20110083605A1 (en
Inventor
Mark Ernest Vermilyea
Peter Michael Finnigan
Dongming Dominic Gao
Bowden Kirkpatrick
Alexander Joseph Vallee, JR.
Stefaan Guido Van Nieuwenhove
Yosang Yoon
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General Electric Co
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General Electric Co
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Priority to US12/575,668 priority Critical patent/US8037843B2/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAO, DONGMING DOMINIC, VAN NIEUWENHOVE, STEFAAN GUIDO, FINNIGAN, PETER MICHAEL, KIRKPATRICK, BOWDEN, VALLEE, ALEXANDER JOSEPH, JR., VERMILYEA, MARK ERNEST, YOON, YOSANG
Priority to JP2010220117A priority patent/JP5679753B2/ja
Priority to CA2715933A priority patent/CA2715933C/en
Priority to EP10186842.0A priority patent/EP2314435B1/en
Publication of US20110083605A1 publication Critical patent/US20110083605A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/382—Automated fiber placement [AFP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres

Definitions

  • the invention relates generally to systems for applying and infusing resins for composite materials and, more particularly, to systems for controllably applying and infusing resins onto individual fiber tows.
  • Resin infused fiber composite materials are being used increasingly in a variety of diverse industries, such as automotive, aircraft, and wind-energy, in part, because of their low weight and high strength properties. It would be desirable to form complex composite components and/or fiber patterns.
  • current manufacturing processes typically involve the use of fiber pre-forms with subsequent resin infusion, or preimpregnated fiber tows called “prepreg”. Both of these methods have drawbacks.
  • one aspect of the present invention resides in an application and infusion system for applying a resin to one or more fiber tows and for infusing the fiber tows with the resin.
  • Each of the fiber tows is moving at a respective fiber speed.
  • the application and infusion system includes a deposition and infusion system comprising one or more nozzles configured to deposit the resin on a respective one of the fiber tows.
  • the application and infusion system further includes a controller configured to control a flow rate of the resin through each of the nozzles relative to the fiber speed of the respective ones of the fiber tows.
  • the application and infusion system includes a deposition and infusion system comprising a plurality of nozzles, wherein each of the nozzles is configured to deposit the resin on at least one of the fiber tows.
  • the application and infusion system further includes a controller configured to control a flow rate of the resin through each of the nozzles relative to the fiber speed of the respective ones of the fiber tows using feedback based on measurement data of at least one of a resin width and a resin thickness for respective ones of the fiber tows.
  • FIG. 1 schematically depicts in side view, a resin application and infusion system integrated in a fiber placement system
  • FIG. 2 schematically depicts in top view, an example array of fiber tows for the fiber placement system shown in FIG. 1 ;
  • FIG. 3 schematically depicts an example array of nozzles for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 4 illustrates an example nozzle configuration for a deposition and infusion system, for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 5 illustrates another example configuration for a deposition and infusion system, for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 6 illustrates another example configuration for a deposition and infusion system, for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 7 illustrates an example configuration for an infusion enhancer, for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 8 illustrates another example configuration for an infusion enhancer, for use in the resin application and infusion system of FIG. 1 ;
  • FIG. 9 illustrates another example configuration for an infusion enhancer, for use in the resin application and infusion system of FIG. 1 .
  • a system 10 for applying a resin 4 to one or more fiber tows 2 and for infusing the fiber tows with the resin is described generally with reference to FIG. 1 .
  • the invention is not limited to specific resins or fiber types.
  • the resin is an epoxy resin
  • the tows comprise carbon fibers.
  • the resin application and infusion system 10 can be integrated into a fiber placement system 30 to form a composites manufacturing machine 100 .
  • This arrangement enables real-time, inline infusion of an array of dry fiber tows, with control of the resin application (and consequently infusion) rate for each of the tows, based on part specific requirements.
  • the resulting machine 100 can be used to fabricate composite structures, non-limiting examples of which include low weight, high strength aircraft and automotive components.
  • the fiber placement system 30 includes dispensing means 32 for feeding multiple fiber tows 2 , where each of the fiber tows is moving at a respective fiber speed. More particularly, the dispensing means 32 are configured to separately feed each of the tows 2 , such that the tows 2 can be fed at different rates. For example, the fiber speed may be zero in some instances for one or more of the fiber tows, while others of the tows are moving.
  • the dispensing means 32 comprise multiple spools 32 . For ease of illustration only one spool 32 is shown in FIG. 1 .
  • Each of the tows 2 in the array of tows is initially wound on a respective one of the spools 32 .
  • each of the tows 2 passes through a respective eyelet 34 .
  • only one eyelet 34 is shown in FIG. 1 .
  • typically one eyelet 34 is provided for each of the tows 2 in the array.
  • the tows 2 then move through a width-controlling roller 36 .
  • FIG. 2 schematically depicts in top view, an example array of fiber tows 2 arranged on the roller 36 .
  • the roller 36 typically includes multiple notches (not shown) for receiving and guiding respective ones of the fiber tows 2 , which are shaped to provide control over the tow width exiting the roller.
  • the example array in FIG. 2 comprises eight tows
  • the invention is not limited to a specific array size or tow count, and for certain applications it may comprise less than eight tows, and for other applications may comprise more than eight tows.
  • the fiber tows 2 move from the width roller 36 to the application and infusion system 10 .
  • the application and infusion system 10 includes a deposition system 11 comprising one or more nozzles 12 configured to deposit the resin 4 on a respective one of the fiber tows 2 .
  • An example array of nozzles 12 is shown in FIG. 3 .
  • one nozzle is provided for each of the fiber tows 2 .
  • the invention is not limited to any specific arrangement of nozzles. Additional aspects of the deposition and infusion system 11 are discussed below with reference to FIGS. 4-6 .
  • the application and infusion system 10 further includes a controller 14 configured to control a flow rate of the resin through each of the nozzles 12 to provide the desired resin content based on the fiber speed of the respective ones of the fiber tows 2 .
  • the controller 14 may exchange information with the fiber placement system 30 , as indicated in FIG. 1 , to optimize the infusion for any laydown sequence. While separate controllers may be employed for the application and infusion system 10 and for the fiber placement system 30 , this control integration is required.
  • the controller 14 may comprise one or more processors. It should be noted that the present invention is not limited to any particular processor for performing the processing tasks of the invention.
  • processor is intended to denote any machine capable of performing the calculations, or computations, necessary to perform the tasks of the invention, and to control the mechanical and electrical devices in the invention.
  • processor is intended to denote any machine that is capable of accepting a structured input and/or of processing the input in accordance with prescribed rules to produce an output, as will be understood by those skilled in the art.
  • the application and infusion system 10 may further include an infusion enhancer 19 for enhancing the infusion of the fiber tows 2 with the resin 4 . Additional aspects of the deposition and infusion system 11 are discussed below with reference to FIGS. 7-9 .
  • the controller 14 is further configured to control the flow rate of the resin through each of the nozzles 12 using feedback based on measurement data of resin width and/or resin thickness for respective ones of the fiber tows 2 .
  • the application and infusion system 10 further includes one or more sensors 16 for monitoring at least one of the resin width and the resin thickness. Although only one sensor 16 is indicated in FIG. 3 for ease of illustration, multiple sensors 16 may be employed, and in one non-limiting example, one sensor 16 is provided for each of the fiber tows 2 .
  • Example sensors include optical or contact sensors.
  • the deposition system 11 further comprises one or more computer controlled pumps 18 .
  • each of the pumps 18 is configured to supply the resin 4 to respective ones of the nozzles 12 . More particularly, a separate pump 18 is provided for each of the nozzles 12 , for the illustrated example. As indicated, each of the pumps 18 is controlled by the controller 14 . In other configurations, at least one of the pumps 18 may be equipped with multiple valves (not shown) to control flow of the resin from the pump 18 to multiple nozzles 12 . For example, each of the pumps 18 may be used to deliver resin to multiple nozzles 12 . In one non-limiting example, the pumps 18 are positive displacement pumps. In particular examples, positive displacement pumps with little leakage are employed. The pump(s) 18 may be connected to the nozzles 12 by tubing or pipes (not shown).
  • the controller 14 is further configured to receive fiber feed rate signals for the respective fiber tows 2 and to control the pumps 18 based at least in part on the fiber feed rate signals for the respective ones of the fiber tows.
  • the fiber tows have different fiber feed rates, such that the controller 14 applies different control signals to the respective pumps 18 .
  • the fiber speed may be zero in some instances for one or more of the fiber tows.
  • the fiber feed rate signals are read from a metering roller (not shown). The metering roller could be adjacent to spool 32 in FIG. 1 or elsewhere along the tow path.
  • FIGS. 4-6 illustrate three example configurations for the deposition and infusion system 11 .
  • the nozzles 12 are configured to deposit the resin on only one side 1 , 3 of the fiber tows 2 . More particularly, for the illustrated arrangement, the nozzles 12 are configured to deposit the resin 4 on only the upper side 1 of the fiber tows 2 .
  • the example deposition and infusion system 11 further includes multiple rods 17 oriented parallel to one another in a direction substantially transverse to a feed path of the fiber tows 2 .
  • the nozzles 12 are disposed between the rods 17 , and the rods 17 are configured to press the fiber tows 2 against the nozzles 12 .
  • Example materials for the rods 17 include hardened steel or other metals with hard coatings; rods should be smooth to limit the drag and resulting fiber tension as well as wear.
  • the position of the nozzle relative to the rods can be optimized to provide the required pressure and residence time to accomplish infusion while limiting the fiber tension to a desired value.
  • the nozzles 12 are configured to deposit the resin on both an upper side and a lower side 1 , 3 of the fiber tows 2 .
  • the deposition and infusion system 11 further includes a rod 17 oriented in a direction substantially transverse to a feed path of the fiber tows 2 .
  • the nozzles 12 are arranged in two rows, and the rod 17 is disposed aft of the two rows of nozzles 12 .
  • the nozzles 12 in the first rows are configured to deposit the resin 4 on the lower sides 3 of the fiber tows 2
  • the nozzles 12 in the second row are configured to deposit the resin on the upper sides 1 of the fiber tows.
  • the first row of nozzles may deposit resin on the upper sides of the tows
  • the second row of nozzles may deposit resin on the lower side of the tows.
  • the rod 17 is configured to press the fiber tows 2 against the nozzles 12 .
  • the infusion depth into the tow from each face can be roughly half of that for single-sided infusion.
  • the deposition and infusion system 11 further includes multiple rods 17 oriented parallel to one another, in a direction substantially transverse to a feed path of the fiber tows 2 .
  • the illustrated arrangement includes two rods 17 .
  • the nozzles 12 are arranged in two rows disposed between the two rods 17 .
  • the nozzles 12 in the first row are configured to deposit the resin 4 on the lower sides 3 of the fiber tows
  • the nozzles 12 in the second row are configured to deposit the resin on the upper sides 1 of the fiber tows 2 .
  • the first row of nozzles may deposit resin on the upper sides of the tows, and the second row of nozzles may deposit resin on the lower side of the tows.
  • the rods 17 are configured to press the fiber tows 2 against the nozzles 12 . This configuration provides additional contact length along the arc of the upstream nozzle compared with the arrangement in FIG. 5 . This additional contact length should promote improved infusion.
  • FIGS. 7-9 illustrate three example configurations for the infusion enhancer.
  • the specific configuration of the infusion enhancer 19 may vary based on the application.
  • the infusion enhancer 19 comprises a pair of platen 22 .
  • the fiber tows 2 extend between the platen 22 .
  • the platen 22 press the resin into the fiber tows 2 , thereby enhancing the infusion of the resin into the tows.
  • the infusion enhancer 19 comprises multiple rods 24 oriented parallel to one another in a direction substantially transverse to a feed path of the fiber tows 2 .
  • the rods 24 may be formed of hardened steel or other metals with hard coatings; rods should be smooth to limit the drag and resulting fiber tension as well as wear.
  • the position of the nozzle relative to the rods can be optimized to provide the required pressure and residence time to accomplish infusion while limiting the fiber tension to a desired value.
  • the fiber tows 2 extend below the first rod, between the rods, and above the second rod, such that the rods press the resin at least partially into the fiber tows.
  • the rods 24 may be configured as shown in FIG. 9 . The arrangement of FIG.
  • FIG. 9 is similar to that of FIG. 8 , except that the fiber tows extend above the first rod, between the rods, and below the second rod, such that the rods press the resin at least partially into the fiber tows.
  • the arrangements shown in FIGS. 7-9 provide various trade-offs between the length of tow being enhanced and the resulting drag.
  • the application and infusion system 10 further includes a heat source 26 configured to heat the fiber tow 2 before the resin is deposited.
  • the deposition and infusion system 11 is disposed in a heated manifold 28 to enhance wetting of the resin onto the tows.
  • a heated manifold 28 is shown, for example, in FIG. 4 and may be included for other embodiments of the deposition and infusion system 11 , as well.
  • the heat source 26 may heat the fiber tows by contact or alternatively may heat the tows indirectly by heating the environment through which the tows pass; radiant heat may also be employed.
  • Non-limiting examples of heat source 26 include quartz lamps, forced hot air in a small channel, or a heated roller.
  • the resin infused fiber tows 2 are fed through a cooling module 38 , for the fiber placement system 30 illustrated in FIG. 1 .
  • cooling module 38 include an air cooler and coolers sold under the trade name Vortex Coolers by ITW Air Management, having a place of business in Cincinnati, Ohio.
  • the cooling module cools the resin infused tows to a temperature in a rage of about 40 F to about 70 F.
  • the cooled, resin-infused fiber tows 2 are then taken up on a mandrel 40 , to be used as pre-impregnated fiber to form a resin infused fiber structure (not shown).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Robotics (AREA)
  • Nonwoven Fabrics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Treatment Of Fiber Materials (AREA)
US12/575,668 2009-10-08 2009-10-08 Resin application and infusion system Active 2029-10-14 US8037843B2 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US12/575,668 US8037843B2 (en) 2009-10-08 2009-10-08 Resin application and infusion system
JP2010220117A JP5679753B2 (ja) 2009-10-08 2010-09-30 樹脂塗工・注入システム
CA2715933A CA2715933C (en) 2009-10-08 2010-09-30 Resin application and infusion system
EP10186842.0A EP2314435B1 (en) 2009-10-08 2010-10-07 Resin application and infusion system

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US12/575,668 US8037843B2 (en) 2009-10-08 2009-10-08 Resin application and infusion system

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US8037843B2 true US8037843B2 (en) 2011-10-18

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EP (1) EP2314435B1 (ja)
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US20120073726A1 (en) * 2010-09-24 2012-03-29 General Electric Company Resin Delivery, Application and Infusion System and Integrated Layup System and Method of Use
US8522849B2 (en) 2010-09-24 2013-09-03 General Electric Company System and method for the automated delivery and layup of resin infused fibers
EP3141378A3 (en) * 2015-08-12 2017-05-03 General Electric Company System and method for controlling at least one variable during layup of a composite part using automated fiber placement

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DE102011100640A1 (de) 2011-05-05 2012-11-08 Compositence Gmbh Verfahren und Vorrichtung zum Herstellen von Fasergelegen und Bauteilvorformlingen aus Fasern
DE102011082192B4 (de) * 2011-09-06 2022-10-06 Bayerische Motoren Werke Aktiengesellschaft Verfahren und Vorrichtung zum Herstellen von Prepregs aus Wickelverfahren
DE102012102841B3 (de) * 2012-04-02 2013-07-11 Institut Für Verbundwerkstoffe Gmbh Verfahren zur Präparation eines Roving
DE102012007439A1 (de) 2012-04-13 2013-10-17 Compositence Gmbh Legekopf und Vorrichtung und Verfahren zum Aufbau eines dreidimensionalen Vorformlings für ein Bauteil aus einem Faserverbundwerkstoff
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FR3016827B1 (fr) * 2014-01-24 2016-02-05 Coriolis Composites Procede de realisation de preformes a partir de fibres avec application en ligne d'un liant, et machine correspondante
KR20180057364A (ko) * 2016-11-22 2018-05-30 주식회사 하이인텍 섬유 프리폼 제조 장치
CN110757832B (zh) * 2019-11-04 2021-06-29 西南石油大学 一种玄武岩纤维缠绕复合管成型装置
CN113334628B (zh) * 2021-06-28 2023-08-01 四川省新万兴碳纤维复合材料有限公司 气浮型辊压连续纤维预浸料生产装置
DE102021123510A1 (de) * 2021-09-10 2023-03-16 Schmidt & Heinzmann Gmbh & Co Kg Produktionsvorrichtung, insbesondere SMC-Produktionsvorrichtung, zu einer Herstellung von duroplastischen Halbzeugen

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Cited By (4)

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Publication number Priority date Publication date Assignee Title
US20120073726A1 (en) * 2010-09-24 2012-03-29 General Electric Company Resin Delivery, Application and Infusion System and Integrated Layup System and Method of Use
US8522849B2 (en) 2010-09-24 2013-09-03 General Electric Company System and method for the automated delivery and layup of resin infused fibers
EP3141378A3 (en) * 2015-08-12 2017-05-03 General Electric Company System and method for controlling at least one variable during layup of a composite part using automated fiber placement
US10399276B2 (en) 2015-08-12 2019-09-03 General Electric Company System and method for controlling at least one variable during layup of a composite part using automated fiber placement

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EP2314435B1 (en) 2020-05-06
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CA2715933C (en) 2018-01-02
US20110083605A1 (en) 2011-04-14
JP2011079310A (ja) 2011-04-21
EP2314435A3 (en) 2017-11-22
EP2314435A2 (en) 2011-04-27

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